Electrical gremlins

 
 
 
 
 
 
soontobetravelling
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Electrical gremlins

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Posted: 10.03.2025  ·  #1
Thought I'd share my electrical gremlin journey so far, with some still tbc details!

Starter issues:
Short version: intermittent starter issues, including no power on key turn, or rough start,engine code referring to circuit 87, and algorithm error.

Replaced battery - no difference.

Found:
- slight corrosion on 3 relays, very slight -light blue colouring at base of pins.
- A lot of rust around nuts on power distribution terminals
- a melted insulation sheath on starter cable (suspecting 'common' y cable failure on sprinter)

So far - replaced all relays and cleaned board with electrical contact cleaner.

Next steps is replacing terminals and nuts for nice clean connections.

Upgrade y cable but mechanic wants to do that as he wants to explore the melted insulation to make sure no other faults in the line.

Reverse camera:
- didn't like the head unit and suspected parasitic drain, so just disconnected it as reverse camera wasn't working anyway.
- pulled off rear left light out of interest and found a loose red cable with tape on it. Not sure if the tape used to hold it in place, or if it has been removed and insulated for a good reason. Can't see anywhere it might have been connected to, but suspect this is the 12v live for the reverse camera. Further tests to be conducted! Thinking of having the boss put it into reverse and find the reverse live, splice it in, and see does that bring the camera to life.

If anyone has any suggestions around anything I'm all ears! Just figured a problem shared is a problem halved 🤣🤣

Have photos of everything if of interest too!

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soontobetravelling
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Re: Electrical gremlins

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Posted: 10.03.2025  ·  #2
Actually, I have a more specific question if anyone has any insight.

First I was wrong in above, it's not the y cable that melted through the insulation. It's the cable connected at point 6 in the power distribution module. This is bridged not fused..

There was a split charge relay fitted, this one https://www.12voltplanet.co.uk…A8_HMV_7jk

Which notes that it's bidirectional...

Is there a world where the solar pv could've sent too much to the battery positive and it diverted across that bridge and melted the wire? I get the split relay is voltage controlled.. but could the solar have diverted too many amps?

Or am I taking nonsense....


Not a future problem, I've separated them and will fit a b2b or something in the future. Just a thought Nd wondered if it had any validity


soontobetravelling
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Re: Electrical gremlins

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Posted: 10.03.2025  ·  #3
Sorry, 3 posts talking to myself is excessive....

HOWEVER I realised my error in that the split relay is fused... Which would've presumably broken if an excessive amperage went through.

I will be checking that though...

And yes, I have started a picture of a wiring diagram I'll eventually get to share with you lovely folk. :D


vino
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Re: Electrical gremlins

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Posted: 11.03.2025  ·  #4
Have you a regulator on the solar panel ?


soontobetravelling
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Re: Electrical gremlins

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Posted: 11.03.2025  ·  #5
Yep, epever mppt controller!

Connected to panels and battery, but 12v systems connect to battery not controller!


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Re: Electrical gremlins

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Posted: 11.03.2025  ·  #6
HarryML
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Re: Electrical gremlins

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Posted: 11.03.2025  ·  #7
soontobetravelling
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Re: Electrical gremlins

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Posted: 11.03.2025  ·  #8
Leisure batteries are not lithium, they're AGM, and the earth strap in the front is on my inspection list but not yet checked no!


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Electrical gremlins

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Posted: 11.03.2025  ·  #9
Quote by HarryML

Have you checked your earthing arrangements?


And all the battery pole connections, remove lean refit, there will also probably be a multi wire earth/ground connection around the engine bay and another for the Habitation system. All worth looking at.


soontobetravelling
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Re: Electrical gremlins

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Posted: 17.03.2025  ·  #10
 


Mightve f*** the upload of photos, but mild corrosion on the earth strap, if you can see it! Warrant a replacement? I'm thinking so, won't start without the Noco boost now, which is a deterioration...!


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Electrical gremlins

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Posted: 17.03.2025  ·  #11
With the amount of rust around, I would think/suggest you have serious earth problems, also as I have suggested, you should check all the Earth/Grounding around the Van.
Before you do anything else, If you have a set of jumpleads, connect one from battery earth ( make sure it's clean) to the body of the starter and see if that helps with the starting, that will give you a clear indication if you have a bad engine to chassis grounding, have someone try starting while you watch that there is no arcing from either the battery or starter body,

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Re: Electrical gremlins

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Posted: 17.03.2025  ·  #12
Thanks a million Sprinter, appreciate the reply! All others look good! that one stood out. Great idea, Will see if I can reach the leads around to it!

On the rest, Yep, lots of surface spots etc hoping to get a dinitrol treatment on the chassis (unless there's other recommendations!)


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